Metallized products and foils and method of forming the same



April 23, 1963 F. H. LASSITER 3,036,879

METALLIZED PRODUCTS AND F OILS AND METHOD OF FORMING THE SAME Filed March 5. 1958 2 Sheets-Sheet 1 FUEL SOURCE INVENTOR FREDEIZIC H. LASSIT'EP.

g y fiamimhlwg ATTORNEYS April 23, 1963 F. H. LASSITER METALLIZED PRODUCTS AND FOILS AND METHOD OF FORMING THE SAME Filed March 5 1958 2 Sheets-Sheet 2 R Y O i E m 0 MW m m J m H w R D M m r United States Patent 3,086,879 METALLIZED PRODUCTS AND FOILS AND METHOD 0F FORMING THE EAME Frederic H. Lassiter, 527 Lexington Ave, New York, N.Y. Filed h Iar. 5, 1958, Ser. No. 719,403 Claims. (Cl. 117-38) This invention relates to a foil or metallized product having a smooth, highly reflective, substantially continuous surface thereon and a method of forming the same. This application is a continuation-impart of my copend ing application, Serial Number 699,669, filed on November 29, 1957, now US. Patent No. 3,055,768, and entitled Metallized Product and Method of Forming the Same. More particularly, this invention relates to a method tfor depositing molten metal onto a base material and a product resulting therefrom having a more uniform, even and continuous metal surface thereon than has been heretofore obtainable.

In my said copending application, I disclosed a product having a highly specular, substantially continuous metallized coating thereon, and a method for forming the same by depositing molten metal, such as aluminum, onto a Web base and, subsequently, calendering this metallized base. Now, it is well known in the art that molten metal such as: aluminum can be sprayed by nozzles, in some cases, onto a web base material Without heat damage to such material. Consequently, in the process disclosed in my said copending application, spraying by nozzles can be used in forming metallized webs. However, this sometimes presents certain undesirable features in the practice of my invention. For instance, the spray necessarily consists of particles of various sizes which results in a highly irregular metal coating. Furthermore, certain areas of the sprayed web have double coatings of particles due to the overlapping of the sprays in order to insure coverage of the base material. Finally, such spray particles are randomly deposited, making it difficult to obtain a continuous coating on the web. Most of these possible disadvantages can be overcome in the subsequent calendering operation by increased pressure on the calender rolls. However, excessive pressure, in many cases, tends to damage the Web material and also produces work hardness causing brittleness in the metal coating as is well known in the art of metal working.

With the above problems in mind, I have developed a method of depositing molten metal particles onto a web base material in a uniform manner. 'In this method, I generally employ an intaglio roll to pick up predetermined amounts of molten metal from a vessel of molten metal and to subsequently deposit the molten metal onto the web material. This new method results in substantially more uniform particles of molten metal being deposited onto the Web and in a more even and substantially continuous particulate mass.

With the foregoing material in mind, it is the primary object of this invention to provide an improved method =for depositing particles of molten metal onto a web base material.

It is another object of this invention to provide an improved method of forming a uniform and continuous metal coating on a web base material.

It is still another object of this invention to provide a method for forming a metallized web material which necessitates less calendering pressure in iorming brilliant, highly reflective metal foil, foil paper products and the like.

It is still another object of this invention to provide a method for producing various utilitarian and decorative metallized products and foils heretofore unobtainable.

3,86,879 Patented Apr. 23, 1963 It is still another object of this invention to produce an improved metal foil or metallized product having a highly specular, substantially continuous metal surface thereon.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which- FIGURE 1 is a schematic elevational view of the first form of the invention showing a web material being coated on both sides and employing an intaglio roll for depositing molten metal particles onto the web by contact therewith;

FIGURE 2 is a schematic elevational View of the second form of the the invention showing a web material being coated on only one side and employing an intaglio roll for depositing molten metal particles onto an intermediate smooth roll which, in turn, deposits the metal onto the web by contact therewith;

FIGURE 3 is a schematic elevational view of the third form of the invention showing a web material being coated on one side and employing an intaglio roll for depositing molten metal particles onto the web by centrif ugal tforce;

FIGURE 4 is a schematic elevational view of the fourth form of the invention showing a web material being coated on one side and employing an intaglio roll for depositing molten metal particles onto the web by centrifugal force with a feed roll for feeding the molten metal onto the intaglio roll;

FIGURE 5 is a schematic view of another modified form of the invention showing the molten metal coating being applied to only one side of an endless web base material and showing the metal coating subsequently being stripped therefrom to form foil;

FIGURE 6 is a greatly enlarged fragmentary vertical sectional view showing the two contacting intaglio rolls in FIGURE 4;

FIGURE 7 is an enlarged isometric fragmentary view of the face of the smaller or upper intaglio roll in FIG- URE 4 and the partially immersed intaglio rolls in FIG- URES 1, 2 and 3;

FIGURE 8 is an enlarged isometric fragmentary view of the face of the larger or lower feed roll in FIGURE 4 drawn on the same scale as the showing in FIGURE 7;

FIGURE 9 is a greatly magnified fragmentary isometric view of a web material with metal deposited thereon by an intaglio cylinder with a design similar to that shown in FIGURE 7;

FIGURE 10 is a vertical sectional view taken along line 10-10 in FIGURE 9; and

FIGURE 11 is a fragmentary vertical sectional view of the metallized web in FIGURE 10 after calendering.

The term calendering herein used throughout the specification and claims encompasses the compacting, smoothing, kneading, polishing, buffing, etc., necessary to give the foil or metallized product the desired characteristics as determined by the web base material and metal used and the end result desired. Accordingly, this term is not to be restricted to calender rolls such as shown in the drawings for illustrative purposes only, but is to include any comparable or equivalent type of apparatus for performing the same or similar results.

The term highly reflective herein used throughout the specification and claims is used to characterize the high luster and brilliance of applicants silver-like product and to differentiate the same from the dull gray products in the prior art formed from depositing molten metal such as aluminum. Specular gloss readings on a group of applicants aluminum coated specimens made from the method disclosed in my above-mentioned copending application, Serial Number 699,669, using a Hunter multipurpose reflectometer with a green filter and S-diaphragm setting at aosasrs a 75 degree angle were 75.3% to 79.7% (substantially the same as conventional aluminum foil paper on cigarette packages) based on a highly polished mirror as the standard for 100%. Ithas been determined that similar or, in some cases, higher specular gloss readings are more readily obtainable on products formed in accordance with the instant invention. Products formed in accordance with the prior art showed specular gloss readings of 16% to 41%.

In no case have prior art specimens exhibited any brilliance remotely approaching the high readings of applicants product or the silvery appearance thereof.

Referring now more specifically to the drawings and particularly FIGURE 1, reference numeral 19 designates a web base material which may be in the form of paper, paperboard, textile fabric or any suitable fibrous web material. The web material is shown wound on a suitable let-oil roll 11 from which the web material is being withdrawn and, in turn, Wound onto a suitable take-up roll 12 after being metallized in a manner to be subsequently explained in detail.

Spaced apart receptacles or chambers 13 and 13' are positioned beneath the path of travel of the web material 10 adjacent opposite surfaces thereof and contain a quantity of molten metal 14 and 14, heated and maintained at substantially a uniform level at all times by any suitable means, not shown. Intaglio rolls 15 and 15' are rotatably mounted by any suitable means in chambers 13 and 13 so that they are partially immersed in the molten metal 14, 14' and positioned below the web and in contact therewith, and preferably have the outer or distal edges of the intaglio designs terminating substantially coextensive with the opposite side edges of the web. In some cases it might be desirable to provide a composite or segmental roll wherein the segments are axially spaced from each other to obtain a desired decorative effect, such as stripes, for example.

In small scale operation, the temperature of the molten metal 14, 14' is usually sufiicient to heat the intaglio rolls 15, 15' to a high enough temperature to enable the metal picked up by such rolls to remain molten until deposited. However, in larger scale operations, it may be necessary to heat these rolls by any suitable means, not shown, since it is imperative that the metal be deposited onto the web material 10 in a molten state.

Suitably cooled rolls 16, 16 may be provided and positioned in contact with the web 10 immediately above the intaglio rolls 15, 15', respectively, and preferably mounted to insure the contact of the web material 16* with the molten metal particles in the intaglio roll design on the intaglio rolls :15, 15'. The rolls 16, 16, for example, may be constructed to have water or the like circulating internally thereof to maintain the periphery of the rolls in a cooled condition at all times which serves to dissipate the heat from the molten metal applied to the web. Thus, heat injury or damage to the web may be prevented by the rolls 16, 16'. It may also be desirable to provide somewhat resilient coverings such as rubber or the like for the rolls l6, 16' to further insure contact of the web with all of the molten particles in the intaglio roll design of the rolls 15, 15'.

As shown in FIGURE 1, web material 10 is withdrawn from let-off or supply roll 11 and directed between intaglio roll 15 and roll 16, both of such rolls preferably being driven at the same peripheral speed as each other and normally at a peripheral speed equivalent to the linear speed of the web material 10. Molten metal is picked up by the intaglio roll 15 as it rotates in the bath of molten metal 14. A scraper or doctor blade 17 wipes the molten metal from the periphery of intaglio roll 15, leaving molten metal only in the recesses forming the intaglio design thereon. Upon contact by intaglio roll 15 with the web 10, the molten metal in the intaglio design thereof transfers to the web 10 and forms a pattern thereon similar to the intaglio pattern on roll 15, as shown in FIGURES 9 and 10.

Intaglio roll 15 can be provided with a design similar to that shown in FIGURE 7. This design, for example, consists of a multitude of uniform minute pockets or recesses in uniform spaced relation on the face of such roll. Thus, the transfer of the molten metal from these pockets onto the web lltl results in a uniform particulate mass of metal being deposited evenly thereon.

After the coated web passes intaglio roll 15, a pair of horizontally positioned, but vertically arranged, guide rolls 2t), 21 reverse the path of travel of the Web material 19 to permit the opposite side of the web material to pass between intaglio roll 15' and cooled pressure roll 16' and to thus be coated with molten metal in the same manner as the other side of the web. As in the first or previous coating station, a doctor blade 17 is provided for wiping the molten metal from the periphery of intaglio roll 15'.

Upon receiving the second coating, the web material 10 passes through a calendering station wherein one or more pairs of calender rolls 2.2 highly compress and compact the metal coating deposited on the web material 10 while smoothing the same to transform the metal coating from an amorphous or irregular surface to a thin, smooth, highly reflective surface. In some cases, it may be desirable to calender, at least to some degree, the first coating before coating the other side of the web to reduce the compaction otherwise needed if both coatings are initially calendered simultaneously. This would be particularly important in those cases where the web material is readily damageable during calendering unless extreme care is exercised. This can be done, for example, by providing one or more sets of calender rolls at a point between guide rolls 20, 21.

In some cases, it may also desirable to cool the calender rolls 22 by any suitable means, not shown, to obtain higher reflectivity. Cooling for such reason is well known to those familitar with the art .of metal rolling.

Normally, the calendering only slightly compresses the web base material while transforming the surface of each of the metal coatings from an optically dull and roughened appearance to a smooth, specular highly reflective surface.

In some cases, it may be found that the metal coating has become brittle after the calendering operation. Such brittleness is caused by work hardness as is well known to those familiar with the art of metal working. This condition can be relieved, where desirable, by annealing the coating and thus relieving the internal stresses caused by excessive work hardness. For example, the coated web material 10 can be passed through a burner or flame treating unit 23 which heats the metal coating to 400 to 625 degrees F. depending on the amount of Work hardness developed and consequent dwell time required to relieve same (when the coating is aluminum) to perform the annealing operation. For certain types of Web materials, it may be desirable to employ cooling rolls 19, as shown, to prevent heat damage to such webs during the annealing operation. In those cases where the annealing operation destroys or effects the desired surface appearance of the metal coatings, it would be desirable to subseqeuntly calender the metal coated web to restore the desired surface appearance.

Referring now to FIGURE 2 in the drawings, the schematic arrangement as shown therein basically differs over the arrangement shown in FIGURE 1 in that different means are shown for applying the metal. Also, the web material is shown being coated on only one surface thereof for convenience of illustration, it being understood that both surfaces of the web may be coated if so desired. Aside from these two variations, the arrangement in FIGURE 2 is similar to that shown in FIGURE 1, and, accordingly, similar reference numerals suifixed by alphabetical letter a will be employed for similar or identical elements as in FIGURE 1.

Referring now more specifically to FIGURE 2, web

material 100 is shown being withdrawn from a let-otf or supply roll 11a and directed between a roll 16a and a transfer roll 24. As shown, chamber 13a is positioned beneath the path of travel of the web a. The chamber 13a contains a quantity of molten metal 14a. Intaglio roll 15a is rotatably mounted by any suitable means, not shown, in chamber 13a so that it is partially immersed in the molten metal 14a in a similar manner as rolls 15, 15' in FIGURE 1. The transfer roll 24 is rotatably mounted directly above and in contact with, the intaglio roll 15a by suitable means, not shown. Intaglio roll 15a and the transfer roll 24 are driven by suitable means, not shown, normally at the same peripheral speed and in timed relation with each other and at a speed which is equal to the linear speed of the web material 10a.

As the intaglio roll 15a rotates in the molten metal 14a, the metal adheres thereto. A doctor blade 17a, in turn, removes the excess molten metal from the periphery of the intaglio roll 15a, leaving molten metal only in the intaglio design thereon. Upon contact of the intaglio roll 15a with the transfer roll 24, the molten metal deposited in the minute pockets of the intaglio roll 15a transfers onto the substantially smooth face of the transfer roll 24. These deposited molten metal particles are, in turn, deposited in substantially the same pattern onto the web 10a when they come into contact therewith. To aid the transfer of the molten particles from intaglio r011 15a to transfer roll 24, a suitable resilient surface covering on roll 24 may be provided. Such a covering will permit the surface of the roll 24 to be pressed against the upper portions of the molten particles in the recessed portions of the intaglio roll 15a and thus insure the transfer of all of these molten metal particles from roll 15a to roll 24. To aid in depositing the molten metal from the transfer roll 24 onto the web 10:: the roll 16a may be employed to insure contact of the web with the roll 24. It may be desirable, in some cases, to provide a resilient covering such as rubber on this roll 16a to prevent over compression of the metal particles as they are deposited from roll 24 to the web. Roll 16a may also be suitably cooled, if found desirable, in the same manner and for the same reasons discussed above relative to cooling rolls 16, 16' in FIGURE 1.

In some cases it may be undesirable to pass some web materials in direct contact with the intaglio roll because of the possibility of heat damage to such webs. For this reason the metal is transferred from the intaglio roll 15a onto transfer roll 24a and then deposited onto the web 16 instead of directly from the intaglio roll to the web as in FIGURE 1. The temperature of the transfer roll 24 is sufficient to maintain the particles of metal in a molten state, but nevertheless is normally 150 to 200 degrees F. cooler than the intaglio roll 15a. If found desirable, the transfer roll 24 may be constructed to have water or the like circulating internally thereof to insure such a temperature differential of the rolls. In this way, the danger of heat damage to the web material is minimized, while, at the same time, permitting the metal to be deposited in molten condition in a positive manner by direct engagement of the transfer roll 24 with the web 10a.

The coated web 10a is now treated in a similar manner as the web 10 in FIGURE 1 and is shown passing through a calendering station represented by calender rolls 22a, then, when desirable, through an annealing station 23a provided with a cooling roll 19a, and then is wound onto a take-up roll 12a.

Referring now to FIGURE 3 in the drawings, the schematic arrangement shown therein basically differs over the arrangement shown in FIGURE 2 in that different means are provided for depositing the metal coating. Aside from this, the arrangement in FIGURE 3 is similar to that shown in FIGURE 2, and, accordingly, similar reference numerals sufiixed by alphabetical letter 12 6 will be employed for similar or identical elements as in FIGURE 2.

Referring now more specifically to FIGURE 3, the web 10b is shown being withdrawn from a let-off or supply roll 11b and directed beneath a cooling roll 25. As shown, chamber 13b is positioned beneath the path of travel of web 10b and contains a quantity of molten metal 14b. intaglio roll 15b is rotatably mounted by suitable means, not shown, in chamber 13b so that it is partially immersed in the molten metal 14b in a similar manner as the intaglio rolls in FIGURES 1 and 2. In operation, to deposit the metal onto the web 10b, the intaglio roll 15b is shown being rotated in a clockwise direction at a high speed by suitable driving means, not shown. As intaglio roll 15b rotates through the molten metal 14b, molten metal adhering to the periphery thereof is wiped therefrom by a doctor blade 17b, thus leaving molten metal only in the recesses forming the intaglio design of the roll. Centrifugal force created by high peripheral speed of the roll 15b causes these molten metal particles in the recesses forming the intaglio design thereon to be thrown tangentially therefrom and upwardly, as shown in the drawings, onto the web 10b, while still in a molten state. This manner of depositing the molten metal particles by centrifugally casting the same through the atmosphere permits the uniform deposition of the molten particles onto the web without direct contact of the web with the hot surface of the intaglio cylinder. Thus, webs which might readily be damaged by the depositing methods shown in FIGURES l and 2. may readily be coated by this method without being damaged. Also, by this centrifugal spray process, loosely woven textile materials and soft porous materials such as mats or bats of randomly positioned fibrous glass, asbestos fibers, etc. may be uniformly impregnated and coated without compressing the same. This transverse and longitudinal uniform application of molten metal particles has not been possible heretofore with conventional spray nozzle techniques.

To aid in ladening the roll 151) with molten metal, a gear pump assembly broadly indicated by numeral 3 may be employed, as shown, to force molten metal into the recesses forming the design of intaglio roll 15b. The gear pump assembly comprises a housing 4 containing intermeshing gears 5-, 5 driven by suitable means, not shown, and a pipe 6 communicatively connected to the interior of housing 4 to permit a quantity of the molten metal to be withdrawn from chamber 13b into the housing 4 to be forced by gears 5, 5' into and through pipe 7. Pipe 7 is provided with a flared end S which extends the width of intaglio roll 15b in close proximity to the periphery thereof thus serving to direct molten metal under pressure into the design on intaglio roll 15b. In some instances, it is contemplated that the gear pump assembly for ladening the intaglio roll 15!) with molten metal will suflice to fully laden the roll to permit the roll to be rotated outside of a bath of molten metal.

A suitably cooled roll 25 may be provided to cool the Web 10b at the point where the molten metal comes into contact with the web. This roll 25-, for example, can be constructed to have water or the like circulating internally thereof to maintain the periphery of the roll in a cooled condition at all times, and thus serve to dissipate the heat from the molten metal applied to the web to prevent heat injury or damage thereto.

After being coated, the web 10b is now treated in a similar manner as the prior embodiments of the invention and is shown passing through a calendering station rep-resented by pairs of calender rolls 2%, then, when desirable, through an annealing station 23b, provided with a cooling roll 1% and then is wound onto take-up roll 12b.

Referring now to FIGURE 4, in the drawings, the schematic arrangement shown therein basically differs over the arrangement shown in FIGURE 3 in that slightly different means are provided in lieu of a gear pump assembly to insure ladening the intaglio roll with molten metal. As before, similar reference numerals sufi'ixed by the alphabetical letter c will be employed for similar or identical elements.

Referring now more specifically to FIGURE 4, web 100 is shown being withdrawn from a let-off or supply roll 11c and directed beneath a roll 25a which may be cooled by any suitable means, not shown, and employed to cool the web Itlc just as roll 25 is optionally provided in FIGURE 3. As shown, chamber 13c is positioned beneath the path of travel of web 13c and contains a quantity of molten metal 14c. An intaglio feed roll 26 and an intaglio roll 28 are rotatably mounted by suitable means, not shown, in the chamber 130 so that a major portion of intaglio feed roll 26 and a minor portion of intaglio roll 28 is immersed in the molten metal 14c. These rolls 26 and 28 are preferably driven at the same peripheral speeds by any suitable driving means, not shown, and preferably in slight contacting relation with each other (see FIGURE 6) to thereby permit intaglio feed roll 26 to serve as a pump to fully laden intaglio roll 28 with molten metal.

In operation, as shown, intaglio feed roll 26 rotates in a clockwise direction and intaglio roll 28 rotates in a counterclockwise direction. The face of intaglio feed roll 26, as shown in the enlarged fragmentary view thereof in FIGURE 8, consists of relatively large square-shaped pockets or recesses 27 which serve to pick up the molten metal from the bath and force it into the multitude of minute pockets or recesses 29 of intaglio roll 28, the enlarged fragmentary view of which is shown in FIGURE 7. It should be noted that the fragmentary views of the respective intaglio rolls shown in FIGURES 7 and 8 are drawn on the same enlarged scale to clearly illustrate the increased size of the recesses in intaglio feed roll 26 over the size of the recesses in intaglio roll 28. This is further illustrated in FIGURE 6 wherein these rolls are shown in contact with each other.

In operation, as stated above, molten metal is picked up by the intaglio feed roll 26 and forced into the recesses 29 of intaglio roll 28 at the point of contact or nip of these two rolls. A doctor blade 170 then wipes the periphery of intaglio roll 28 thereby leaving molten metal only in the recesses 29 thereof. Centrifugal force created by the high peripheral speed of roll 28 causes the molten metal in the recesses thereof to be thrown onto the web 100 while still in a substantially molten state.

As shown in FIGURE 4, the intaglio feed roll 26 is much larger than the intaglio roll 28. This permits the intaglio feed roll 26 to be rotated at a relatively slow rotary speed in order to pick up larger quantities of the molten metal into the recesses 27 thereof and yet be rotated at the same peripheral speed as the intaglio roll 28 in engagement therewith. Although the intaglio feed roll 26 is substantially larger than intaglio roll 28, the peripheral speeds of the respective rolls are preferably still the same, and of such speed to permit the molten metal on the intaglio roll 28 to be centrifugally cast therefrom.

As in the prior embodiments heretofore described, after coating, the web 10c passes through a calendering station represented by one or more pairs of calender rolls 22c and, if desired, through an annealing station 23c which may be provided with a cooling roll 190 for protecting the web during the annealing operation, and then is wound onto a take-up roll 12c.

Referring now to FIGURE in the drawings, the schematic arrangement shown therein basically differs over the arrangements in FIGURES 1, 2, 3 and 4 in that there is provision of means for stripping the metal coating from the web material to thus form a metal foil. As before, similar reference numerals suflixed by alphabetical letter d will be utilized for similar or identical elements as in the foregoing embodiments.

Referring now more specifically to FIGURE 5, web 30 is shown in the form of an endless blanket or belt, driven by any suitable means, not shown, and moved in a path of travel around guide rolls 31, 32 and 33. This endless belt 36 may be formed of any suitable material to which the molten metal will readily adhere and being of sufficient strength to permit the metal coating to be readily stripped therefrom without damaging the belt or disrupting the metal foil. Preferably this endless web is constructed of stainless steel since it has been determined that desired results may be readily obtained therewith. A chamber 130. is positioned beneath the path of travel of the web 30. This chamber contains a quantity of molten metal 14d and has intaglio roll 15d rotatably mounted therein bysuitable means, not shown. This coating apparatus is substantially similar to that shown in FIGURE 1. It should be noted, however, that if desired, any of the coating apparatuses shown in FIGURES 2, 3 and 4 could be employed in lieu thereof.

As shown, molten metal is deposited onto the lower surface of the web 3)!) upon passing in engagement with intaglio roll 15d. Here, as in FIGURE 1, a roll 16d may be provided positioned in contact with the web 30 immediately above intaglio roll 15d, and preferably mounted to insure contact of the web material 30 with the molten metal particles in the recesses of intaglio roll 15d. Doctor blade 170. is also provided for removing the molten metal from the periphery of the intaglio roll 15d to leave molten metal only in the recesses forming the intaglio design thereon.

The metal coated web 30 is then passed between at least one pair of calender rolls 34 which calender the metal coating deposited on the web material. At this stage, the metal coating may be calendered sufiiciently to produce a highly reflective surface thereon. However, if desired, the metal coating may be calendered to a lesser degree and subsequent to being stripped from the web 30, calendered to form the desired highly reflective product. This is shown in the drawings wherein the metal coating is stripped from the web 30 in the form of foil 36 immediately following its exit from the nip of calender rolls 34 and thereafter is shown being calendered by at least one pair of calender rolls 37. As in the prior embodiments heretofore described, foil 36 is then passed through an annealing station 23d, if desirable, and is subsequently wound onto take-up roll 12d.

Referring now to FIGURES 9, 10 and 11, these views depict the formation of a metallized web material utilizing any of the coating apparatuses previously described. For forming the illustrated product, it is assumed that the intaglio roll for depositing the molten metal onto the web base material has an intaglio design thereon as shown in FIGURE 7.

Now referring more specifically to FIGURES 9 and 10, it should be noted that the molten metal particles P are so deposited on the web base W that the particles are arranged in a complementary pattern corresponding to the recesses 29 forming the intaglio design on intaglio roll 28 (FIGURE 7). It should also be noted that preferably the particles P are deposited at an elevated temperature to permit the particles to flow together somewhat and form a continuous coating on the web W. In this manner, the molten metal particles P are positioned on the web W in predetermined placed relation to avoid any overlapping of the particles as has been the case heretofore when utilizing spray nozzles or the like. Furthermore, the particles P are all of uniform size to present a uniform amorphous or irregular continuous coating on the web W.

Referring now to FIGURE 11 wherein the final end product is shown after being calendered to present a high- 1y reflective surface to the metal coating thereon, it should be noted that the calendaring operation has only slightly compressed or reduced the thickness of the web W while substantially reducing the thickness of the coating. It is apparent, that the thickness of the coating is necessarily considerably reduced from that shown in FIGURE 10 due to the calendering operation moving the peaks or high portions of the metal particles P into the low portions or valleys therebetween in providing a smooth, continuous, highly reflective, specular surface to the metal coating.

Although the description of the invention has been particularly directed to providing a foil-like product or smooth continuous highly reflective metallic surface to a web material, it is to be understood that if so desired, the intaglio roll for depositing the molten metal onto the base material may have any suitable intaglio design thereon to permit the forming of various decorative designs such as stripes or any other suitable design pattern on the base material.

'In the use of spray nozzles, it has been found that up to as high as 80% reduction in thickness of the metal coating may be necessary, in some cases, to obtain the desired product. By using the herein disclosed intaglio methods, this figure can be reduced substantially because of the uniformity of particle size and evenness of coating obtainable through this method.

The choice of coating apparatuses will vary according to the type of web material used and the end product desired. Accordingly, where Webs which are not readily damaged by heat aroused, the direct contact method such as that shown in FIGURE 1 will be appropriate. Where heat damageable webs are used, the methods shown in FIGURES 2, 3 and 4 will normally be preferred.

It should be noted that various combinations of any of the various embodiments of my process represented schematically by FIGURES 1 to 5 may be employed. Accordingly, if it is desired to have the Web coated on both sides, the metal depositing apparatuses represented by FIGURES 2, 3 or 4 could be employed in lieu of either or both of the coating apparatuses shown in FIGURE 1. Furthermore, coating apparatuses such as those shown in FIGURES 2, 3 and 4 could be employed in lieu of the coating apparatuses shown in FIGURE 5.

If necessary or desirable, any of the methods of forming metallized products or foils disclosed herein or, at least the metal depositing step, can be performed under vacuum or non-oxidizing atmospheric conditions to substantially eliminate any undesirable oxidation of the metal particles in their transfer from the molten metal bath onto the web material.

Any type of malleable metal such as aluminum, zinc, copper, tin, gold, silver, etc., and/ or alloys thereof may be used as the metallic coating material if so desired. The only known limiting factor is that the metal or alloy thereof employed must be readily reduced to molten state so as to permit the same to be applied in finely divided molten particles. The temperature necessary for reducing the metal or alloy thereof to a suitable molten state to be readily applied to a web base material will, of course, depend upon the particular type of metal or alloy thereof used. Aluminum, which is the preferred metal, can readily be reduced and applied to a web material by heating the same to about 1200 to 1400 degrees F.

Where work-hardness is present, after calendering, the annealing temperature necessary to relieve the stresses and strains in the metal coating and to permit the molecules thereof to realign will, of course, also depend upon the type of metal or alloy thereof employed. As an example, approximately 400 to 625 degrees F. for aluminum is normally sufficient.

It is thus seen that I have herein disclosed an improved method of producing metallized products and foil by depositing molten metal particles of uniform size onto a base material in uniform placed relation prior to calendering such coating to render it continuous. This newly achieved uniformity of the resultant deposition of molten metal particles obtainable by the use of the intaglio roll method therefore reduces the amount of calendering necessary to obtain the desired end product, and thus reduces the possibility of damage to the Web material in the calendering operation.

In the drawings and specification there have been set forth several embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. A method of forming a metallized product comprising the steps of rotating a suitably designed intaglio roll laden with particles of molten metal, moving a suitable fibrous web material such as paper past the roll, and trans ferring the molten metal from the roll onto the web.

2. A method of forming a metallized product having a highly reflective surface, comprising the steps of rotating a suitably designed intaglio roll, ladening the intaglio design of the roll with molten metal particles during the rotation of the roll, moving a suitable fibrous web material such as paper past said roll, transferring the molten metal from the roll onto the web, and calendering the metallized web to form a highly reflective surface thereon.

3. Ina method according to claim 2 wherein said step of transferring comprises passing the web material in engagement with the intaglio roll for receiving the molten metal therefrom.

4. In a method according to claim 2 wherein the step of transferring the molten metal comprises transferring the metal from the intaglio roll onto another roll, and from there onto the web material by passing the web material in engagement therewith.

5. In a method according to claim 2 wherein the step of transferring comprises rotating the intaglio roll at suflicient speed to centrifugally throw the molten metal onto said web.

6. In a method according to claim 2 wherein the linear speed of the web moved past said intaglio roll is substantially equal to the peripheral speed of said roll so that the molten metal deposited on said web in said transferring step is deposited in substantially the same design as that appearing on said intaglio roll.

7. In a method according to claim 2 wherein the calendered metallized web is subsequently annealed.

8. A method of forming a metallized product having a highly reflective surface, comprising the steps of rotating a suitably designed intaglio roll in a bath of molten metal, picking up molten metal in the intaglio design of said roll, wiping the periphery of said roll to remove any excess molten metal therefrom, moving a suitable fibrous web material such as paper past said roll, transferring the molten metal in said intaglio design onto said web, and calendering the metallized web to form a highly reflective surface thereon.

9. A metallized product made in accordance with claim 8.

10. A method of forming a metallized product having a highly reflective surface comprising the steps of rotating at substantially the same peripheral speeds a suitably designed first intaglio roll partially immersed in a bath of molten metal in engagement with a second larger rotating intaglio roll substantially immersed in said bath to cause the second roll to force molten metal into the intaglio design on the first intaglio roll, removing the excess molten metal from the periphery of the first intaglio roll, maintaining the peripheral speed of said first intaglio roll at a sufiicient speed to centrifugally throw the molten metal therefrom, moving a suitable fibrous web material such as paper adjacent the first intaglio roll, depositing the centrifugally thrown molten metal onto the web to form a metal coating thereon, and subsequently calendering the metallized web to form a highly reflective surface thereon.

References Cited in the file of this patent UNITED STATES PATENTS 1,992,997 Drake Mar. 5, 1935 2,169,638 Gilflllan Aug. 15, 1939 2,210,145 De Bats Aug. 6, 1940 (Gther references on following page) UNITED STATES PATENTS 2,400,304 Hammel May 14, 1946 227 494 Gold J 7 1941 2,405,662 McManus et :al Aug. 13, 1946 2,241,104 Van Der Grinten May 6, 1941 2,414,923 Bawheller J 28, 1947 2,275,148 Hornbeck Mar. 3, 1942 ,8 Talrnage y 1 1 7 2,293,690 Harrigan Aug. 18, 1942 2,47 4 Bi kn ll Aug 1 1 2,312,927 Murray Man 2, 1943 2,582,744 Brennan Jan. 15, 1952 2,331,951 Wright et a1 Oct. 19, 1943. 7 2,690,005 Schoenfeld Sept. 28, 1954 2,351,670 Desch et a1 June 20, 1944 

1. A METHOD OF FORMING A METALLIZED PRODUCT COMPRISING THE STEPS OF ROTATING A SUITABLY DESIGNED INTAGLIO ROLL LADEN WITH PARTICLES OF MOLTEN METAL, MOVING A SUITABLE FIBROUS WEB MATERIAL SUCH AS PAPER PAST THE ROLL, AND TRANSFERRING THE MOLTEN METAL FROM THE ROLL ONTO THE WEB. 